Apparatuses and methods for registering sheet articles

ABSTRACT

Apparatuses and methods are provided for improving handling of sheet articles during processing within sheet processing machines, particularly for apparatuses and methods for registering sheet articles within a sheet or mail processing machine. A registration apparatus can be provided that aligns sheet articles, such as envelopes, by using negative pressure to register the sheet articles. The registration apparatus can have an elongated housing defining a slit therein for receiving a sheet article. At least a portion of a sheet article may be advanced within the slit of the registration apparatus. A negative pressure may be applied within the housing to pull the sheet article into alignment within the registration apparatus.

RELATED APPLICATIONS

This application relates to the U.S. patent application Ser. No. ______,entitled “INSERTER SYSTEMS AND METHODS” filed simultaneously, thedisclosure of which is incorporated herein by reference in its entirety.Further, this application relates to the U.S. patent application Ser.No. ______, entitled “APPARATUSES AND METHODS FOR VARIABLY OPENINGENVELOPES” and to U.S. patent application Ser. No. ______, entitled“CREASE ROLLER APPARATUSES AND METHODS FOR USING SAME”, also filedsimultaneously, the disclosures of which are also incorporated herein byreference in their entireties.

TECHNICAL FIELD

The subject matter disclosed herein relates generally to handling ofsheet articles for processing. More particularly, the subject matterdisclosed herein relates to apparatuses and methods for registeringsheet articles within a sheet or mail processing machine.

BACKGROUND

Increasingly, a widespread need exists in commercial and governmentalinstitutions for sheet processing machines, particularly mail processingmachines, capable of operating at higher operation speeds with highreliabilities and short down-times. Operating sheet processing machinesat or near their maximum capability is critical for optimizing outputand throughput. Delays or inefficiencies in any operation in theprocessing of sheet articles can undesirably affect further operationsdownstream. Since each operation is typically synchronized to theothers, delays in feeding time, as well as in other operations, can beperpetuated throughout an entire sheet processing sequence or line.

Speeds and efficiencies of a sheet processing machine in high speedoperations can be greatly affected by the handling of the sheet articleswithin the sheet processing machine. For example, demands on accuracy ofsheet article positioning and alignment in the course of handling ofsheet articles are greatly increased in high speed sheet or mailprocessing machines. False or inadequate alignment or registrations canresult in misfeeds of sheet articles that can cause delays inprocessing.

A further example relates to processing of creased sheet articles. Whenprocessing creased sheet articles within a sheet processing machine,particular attention needs to be paid to the handling of the creasedsheet articles. The crease of a sheet article can cause the sheetarticle to assume a non-planar position. Thus, the creased sheet articlemay become harder to process within a sheet processing machine. Whenfilling an envelope within an inserter system, for example, the fold ofthe flap of the envelope along its hinge line often causes the envelopeto assume a non-planar position, which makes handling within theinserter system more difficult. Also, the fold of the flap often causesthe flap to block the mouth of the envelope. Thus, it is desirable tohave the envelope assume a more planar position during processing withina sheet processing machine. Complicated mechanisms are currently usedwithin sheet processing machines to force envelopes to assume a moreplanar position during processing. These mechanisms used to forceenvelopes to assume a more planar position during processing can slowdown processing and also cause delays and inefficiencies.

Another example of where the handling of sheet articles within aninserter system can affect delays or inefficiencies relates to thefilling of envelopes. The processes and apparatuses used for openingenvelopes can create a bottle neck within an inserter system. Any delaysor inefficiencies in such processes or apparatuses will likely affectproduction through the entire inserter system. Thus, any improvement inspeeds or efficiencies can greatly affect production of the insertersystem. For example, early steps for preparing the envelopes forinsertion may be beneficial. Also, processing the envelope in a moreeffective manner can improve throughput of the inserter system. Forinstance, maximizing the amount that an envelope is held open isdesirable to prevent unneeded contraction of the sides of the envelopethat can result in misfeeds of insert material, while still holding theenvelope opened wide enough to permit the filling of the envelope. Suchan improvement could increase efficiencies in insertion of insertmaterial into envelopes.

In light of the above, needs exist for improved handling of sheetarticles within sheet processing systems, such as mail processingsystems, particularly with regard to improving throughput and increasingefficiencies within a sheet processing machine.

SUMMARY

In accordance with this disclosure, novel apparatuses and methods areprovided for improving handling of sheet articles during processingwithin sheet or mail processing machines, particularly for apparatusesand methods for registering sheet articles within a sheet or mailprocessing machine. A registration apparatus may be provided that alignssheet articles, such as envelopes, by using negative pressure toregister the sheet articles.

Some of the objects having been stated hereinabove and are addressed inwhole or in part by the present subject matter. Other objects willbecome evident as the description proceeds when taken in connection withthe accompanying drawings as best described hereinbelow.

BRIEF DESCRIPTION OF THE DRAWINGS

A full and enabling disclosure of the present subject matter includingthe best mode thereof to one of ordinary skill of the art is set forthmore particularly in the remainder of the specification, includingreference to the accompanying figures, in which:

FIG. 1 illustrates a schematic view of an embodiment of an insertersystem that can employ an embodiment of the present subject matter;

FIG. 2 illustrates a perspective view of an embodiment of an inserterstation that can employ an embodiment of the present subject matter;

FIG. 3 illustrates a perspective view of embodiments of a variableenveloper apparatus, a registration apparatus, and a crease rollerapparatus according to the present subject matter;

FIG. 4A illustrates a top plan view of an envelope entering the creaseroller apparatus and preparing to enter the registration apparatusaccording to FIG. 3;

FIG. 4B illustrates a top plan view of the envelope residing in theregistration apparatus according to FIG. 3;

FIG. 5 illustrates a perspective side view of the embodiments of creaseroller apparatus and registration apparatus of FIG. 3;

FIG. 6A illustrates an exploded view of an embodiment of theregistration apparatus according to the FIG. 3;

FIG. 6B illustrates a magnified view of the section 1-1 of FIG. 6Ashowing a first end of the registration apparatus;

FIG. 6C illustrates a side view of the first end of the registrationapparatus shown in FIG. 6A;

FIG. 6D illustrates a side view of another embodiment of a registrationapparatus according to the present subject matter;

FIG. 6E illustrates a side view of a further embodiment of aregistration apparatus according to the present subject matter;

FIG. 7A illustrates a cross-sectional side view of the registrationapparatus of FIG. 3;

FIG. 7B illustrates a perspective view of the registration apparatus ofFIG. 3;

FIG. 8 illustrates a schematic cross-sectional view of an embodiment ofa housing of a registration apparatus according to the present subjectmatter;

FIG. 9 illustrates a further perspective view of the registrationapparatus of FIG. 3; and

FIG. 10 illustrates a top plan view of the embodiment of theregistration apparatus according to FIG. 3.

DETAILED DESCRIPTION

Reference will now be made in detail to presently preferred embodimentsof the present subject matter, one or more examples of which are shownin the various figures. Each example is provided to explain the subjectmatter and not as a limitation. In fact, features illustrated ordescribed as part of one embodiment can be used in another embodiment toyield still yet another embodiment. It is intended that the presentsubject matter covers such modifications and variations.

The term “sheet article” is used herein to designate any sheet article,and can include, for example and without limitation, envelopes, sheetinserts folded or unfolded for insertion into an envelope or folder, andany other sheet materials.

The term “mail article” is used herein to designate any article forpossible insert into a mailing package, and can include, for example andwithout limitation, computer disks, compact disks, promotional items, orthe like, as wells any sheet articles.

The term “document set” is used herein to designate one or more sheetarticles and/or mail articles grouped together for processing.

As defined herein, the term “insert material” can be any material to beinserted into an envelope, and can include, for example and withoutlimitation, one or more document sets, sheet articles, mail articles orcombinations thereof.

The present subject matter relates to sheet processing, such as, forexample, mail inserting systems, mail sorting systems, and any othersheet processing systems. For example, FIG. 1 illustrates a planschematic view of an inserter system, generally designated IS. Theinserter system IS can comprise different modules that can be assembledin different arrangements for inserting material into envelopes. Thedifferent modules and inserter system IS can be controlled by acontroller 600. The controller 600 can be computer hardware or software.For example, the controller 600 can include one or more computers,mini-computers, programmable logic controllers or the like.

Inserter system IS can include, for example, an envelope feeder module,generally designated as 100, which feeds envelopes in a direction A intoan inserting station module, generally designated as 300. An assemblystation module 800 can be used to collect one or more sheet articlesand/or one or more mail articles from upstream into a first document setthat can be sent to a staging station 900 before being conveyed in adirection B toward inserting station module 300. In front of or behindeach first document set on a conveying path of the inserter system IS,one or more sheet articles and/or mail articles can be fed on theconveying path to form second document sets as the first document setsmove in direction B so that each first document set and correspondingsecond document sets can be combined together into insert material forinsertion into an envelope.

The second document sets are fed into the conveying path to be combinedwith the first document sets by one or more modules 1000 of enclosurefeeders EF₁, EF₂. Each enclosure feeder module EF₁, EF₂ can include oneor more station feeders for providing second document sets to beincluded in insert material to fill the envelope. Enclosure feeders EF₁,EF₂ can feed second document sets in front of the first document set orbehind the first document set. Further, enclosure feeders EF₁, EF₂ canfeed sheet articles and/or mail articles on top of the first documentset.

In the examples shown, a collating apparatus module 2000, as shown anddescribed in U.S. patent application Ser. No. 11/240,604, filed Sep. 30,2005, the disclosure of which is incorporated herein by reference in itsentirety, can be provided to collate the first and second document setstogether before being feed to the inserting station module 300 where thematerial can then be placed into an envelope. Each filled envelope canthen be directed in direction C₁ into a sealer module 700 afterinsertion has occurred. The envelopes can be sealed in the sealer module700 before they are sent out for metering and mailing. Further, theinserting station module can include an apparatus for diverting defectsin a direction C₂ out of the inserter system IS.

Other modules can be included in the inserter system IS. For example, asheet feeder SF for feeding in sheet articles to be collected in theassembly station 800 is normally positioned upstream of the assemblystation 800. Assembly station 800 can be followed by staging station900. Further, other modules can be placed inside the inserter system ISsuch as a folder module FM, reader module R and an accumulator module AMas are commonly used within the art. These modules can be placedanywhere within inserter system IS where they may be needed for adesired use.

Reader R can be used to read and collect information from sheets passingunder it, for example, from bar codes. Reader R can be in directcommunication with controller 600. Reader R can read information fromsheet articles and/or mail articles to be used by controller 600 tocontrol insertion system IS. The information read by reader R can helpdetermine how a grouping of sheet articles and/or mail articles in adocument set will be processed within inserter system IS. Further, theinformation can be used to determine what other document sets may beneeded in the insert material for any particular envelope. Accordingly,the information can also be used to determine the amount of insertmaterial to be received in each envelope.

According to certain aspects of the present subject matter, aregistration apparatus for aligning a sheet article is provided. Theregistration apparatus includes an elongated housing defining a slitalong at least a portion of a length of the housing for receiving atleast a portion of a sheet article. The housing further defines aninterior in communication with the slit. A vacuum connection can beattached to the housing and can be in communication with the interior ofthe housing. The vacuum connection can be configured for pulling aportion of a sheet article within the slit to align the sheet article.

According to other certain aspects of the present subject matter, amethod of registering a sheet article within a sheet processing machineis provided. The method includes providing a registration apparatushaving a slit therein for receiving a sheet article. A sheet article canbe advanced at least partially within the slit of the registrationapparatus. A negative pressure can be applied within the registrationapparatus to pull the sheet article into alignment within theregistration apparatus.

Inserting station module 300 is shown in more detail in FIG. 2.Inserting station 300 can include a variable envelope opener apparatus,generally designated as 400, for opening the envelope for receipt of theinsert material therein. Variable envelope opener apparatus 400 canoperate to permit an envelope to be opened in different widths dependingon the characteristics of the insert material to be inserted into theenvelope. As envelopes are fed into variable envelope opener apparatus400, the envelopes can pass through a crease roller apparatus, generallydesignated as 200, to help ensure the flap of the envelope entering thevariable envelope opener apparatus 400 does not interfere with theinsertion of the insert material into the envelope. When an envelope isin the variable envelope opener apparatus 400, insert material cantravel on the conveying path including atop deck 410, which helps todirect the insert material into an envelope within the variable envelopeopener apparatus 400. Once the insert material has been inserted intothe envelope, the envelope is conveyed down inserting station 300 to aright-angle-turn apparatus, generally designated as 310, where thefilled envelope can then be conveyed into sealer module 700 as describedabove or can be diverted out of the inserted system IS in direction C₂as shown in FIG. 1 if a defect or problem is detected with the envelope.

FIG. 3 illustrates a perspective view of variable envelope openerapparatus 400 and the crease roller apparatus 200. The variable envelopeopener apparatus 400 includes deck 410 having a first end 412 and asecond end 414. Deck 410 further includes a top side 416 that isconfigured to provide a conveying path 418 for insert material to beconveyed long toward an envelope in which it shall be inserted. Deck 410can include one or more elongated slots 420 for pusher members 422.

As shown in the illustrated embodiment, a pair of elongated slots 420can be aligned down the conveying path 418 or deck 410. In such anembodiment, a pair of insertion pusher members 422, such as pusher pinsor picks, can be conveyed down the parallel slot 420 such that theinsertion pusher members 422 are conveyed parallel to one another toregister the insert material and push the insert material into anenvelope. Insertion pusher members 422 can then convey the envelope ontothe right-angle-turn apparatus 310 to be conveyed to sealing module 700or be diverted out of the inserter system if there is a defect therein.The deck 410 can also include elongated slots 424 in which collectingpusher members (not shown) from downstream in the inserter system IS canbe conveyed. In such an embodiment, collecting pusher members can conveythe insert material along conveying path 418 from upstream until suchpoint that insertion pusher members 422 pick up the insert material tobe conveyed toward the envelope. At such point, the collecting pushermembers descend below conveying path 418 and deck 410.

The deck 410 can include a first platform 427 which overlays a secondplatform 428 and a third platform 429 to form the top surface 416 of thedeck 410. Top side 416 can have insert guides 430 on either side of theconveying path 418 to help guide the insert material toward theenvelope. Insert guides 430 can be adjustable to accommodate differentsized insert material thereby helping to funnel the insert materialtoward the envelope. Flexible tabs 432 can be positioned above top side416 of deck 410 such that the insert material can pass between the tabs432 and top side 416 for the deck 410. Tabs 432 can be attached to theinsert guide such that tabs 432 moves with insert guides 430. Tabs 432can extend under the flap of the envelope but not into the mouth of theenvelope in which the insert material is to be received.

Envelopes fed in direction A can be fed under crease roller apparatus200 by sets of feed rollers 202, 206. The crease roller apparatus canscore envelopes entering the variable envelope opener apparatus 400along the fold of flaps of the envelope to bend the flaps of theenvelopes against the fold. This scoring helps to keep the envelopesopen for insertion of material as described in more detail below.

The sets of feed rollers 202, 206 feed the envelopes into a registrationapparatus, generally designated as 440, that includes a housing 442 anda vacuum connection 444. Registration apparatus 440 registers theenvelopes fed therein by the feed rollers to align the envelopes. Theregistration apparatus 440 and a flat plate 446 hold the envelopes fedinto the registration apparatus 444 in a staging position. Flat plate446 can be moved back and forth by an actuator 448 between an extendedposition and a retracted position. When flat plate 446 is extended, flatplate 446 is in a holding location. When flat plate 446 is retracted,flat plate is in an entry location. A first drop bar 450 is positionedabove flat plate 446 and a second drop bar 452 is placed above thestaging position between flat plate 446 and registration apparatus 440.As flat plate 446 is moved from the holding location to the entrylocation, first drop bar 450 and second drop bar 452 push each envelopeinto an insertion position where a holding system holds that envelope. Afeeding guide, generally designated as 454, which can include a rotaryactuator 456 can rotate fingers into the mouth of each envelope in theinserter position to hold it open while insertion pusher members 422push the insert material into the envelope and then carry the envelopeto right-angle-turn apparatus 310 shown in FIG. 2. Depending on theamount of material to be inserted into the envelopes, envelopes can beheld open in various degrees by shifting deck 410 and feeding guide 454between different locations.

Although the registration apparatus 440 is described relative tooperation with an envelope, other sheet articles, for example, foldedsheet articles, will operate in a similar manner. FIGS. 4A and 4Billustrate the feeding of an envelope E into a staging position,generally designated as 460, within variable envelope apparatus 400.Envelope E has a body portion BP and a flap F. A fold FL is createdbetween body portion BP and flap F along a crease or hinge line HL. Bodyportion BP can have a face side FS on which an address window usuallyresides or an address is usually printed. Body portion BP also has abackside. The backside of the body portion BP is where flap F can besecured to body portion BP to close envelope E.

Envelope E can be fed from the envelope feeder apparatus 100 (seeFIG. 1) such that envelope E has face side FS of body portion BP ofenvelope E facing upward. The operation of the registration apparatus440 is not affected by the flap orientation (flap up or down) nor is itaffected by the location of the address window or address printing (topor bottom of the envelope). Flap F of envelope E extends outward fromhinge line HL away from body portion BP of envelope E. The first set offeed rollers 202 transports envelope E and, along with the second set of206 feed rollers, feed envelope E into registration apparatus 440 suchthat flap F resides on flap plate 446. A negative pressure can becreated through housing 442 of registration apparatus 440 by vacuumconnection 444 to register envelope E within registration apparatus 440.As shown in FIG. 4B, envelope E is, at this point, aligned under firstdrop bar 450 and second drop bar 452. First drop bar 450 and second dropbar 452 can be used to help push envelope E from staging position 460into an insertion position. The envelope is extracted from theregistration device before insertion of material into the envelope bythe downward action of the second drop bar 452. While envelope E isbeing fed by the sets of feed rollers 202, 206 into registrationapparatus 440, crease roller apparatus 200 can score envelope E alongthe hinge line HL to bend flap F of envelope E in an inverted directionfrom that of the original fold along hinge line HL.

After the envelope has been scored by crease roll apparatus 200, theenvelope can be fed into registration apparatus 440 for registeringwithin variable envelope opener apparatus 400. As can be seen in FIGS.4A, 4B, and 5, crease roll apparatus 200 and the sets of feed rollers202, 206 are aligned to feed the envelope along direction A so that therear end of the envelope resides in registration apparatus 440 and theflap end of the envelope resides on flap plate 446, thereby holding theenvelope in a staging position 460. As mentioned above, registrationapparatus 440 can include housing 442 and vacuum connection 444. Housing442 defines a slit 462 along at least a portion of the length of housing442 for receiving a portion of an envelope being fed into housing 442.Slit 462 can be in a straight line within housing 442. Further, slit 462can have a convex or a concave shape. Housing 442 can have a first end464 and a second end, generally designated as 466. Vacuum connection 444can be attached to housing 442 at second end 466 of housing 442. Thoseskilled in the art may attach the vacuum source at other locations alongthe housing 442, instead of using an end cap as shown, without affectingthe performance of the registration apparatus.

First end 464 of housing 442 can define an entrance 468 for slit 462 forreceiving an envelope fed by the set of feed rollers 206. Vacuumconnection 444 can provide a negative pressure from a vacuum sourcewithin housing 442 that aligns the envelope within the slit 462. Asensor 470 can detect the presence of an envelope within stagingposition 460 when the envelope resides in registration apparatus 440 andon top of flap plate 446. Once the envelope is received within stagingposition 460, first drop bar 450 and second drop bar 452 can be readiedto push the envelope out of staging position 460 and into the insertionposition within variable envelope opener apparatus 400. The vacuumsource can be left on during the extraction of the envelope from theregistration device. Alternatively, the vacuum source can be turned offwhen the drop bar 452 is actuated to extract the envelope and put itinto the insertion position.

As can be seen in the exploded view of FIG. 6A, housing 442 can be atubing having a front wall 472, a back wall 474, a top wall 476 and abottom wall 478. The front, back, top and bottom walls 472, 474, 476,478 can define a chamber, generally designated as 480, that can runlength L of housing 442. Housing 442 also can define an opening 482 onfirst end 464 and an opening 484 on second end 466, both of which are incommunication with chamber 480. Slit 462 can reside in front wall 472 toprovide access to chamber 480.

Chamber 480 can extend the full length L of housing 442 or it can extendfor a partial distance within length L. Similarly, the slit 462 canextend the full length L of housing 442 or it can extend only a partialdistance along the length L. Slit 462 can also extend only along aportion of the length of chamber 480. As previously mentioned, housing442 can define a convex slit 499A or a concave slit 499B as shown inFIGS. 6D and 6E respectively. By using these alternative shaped slits499A and 499B, the beam strength of the envelope in the staging area 460can be increased, if required.

As in the embodiment shown in FIGS. 6A and 6B, a sealing block 486 canbe secured within opening 482 of first end 464 of housing 444. Sealingblock 486 can help direct the pull of the negative pressure createdthrough vacuum connection 444 and also help direct the envelope intoslit 462 and chamber 480.

One or more holding pins 488 can be inserted above slit 462 through atleast one of front wall 472 or back wall 474. Holding pins 488 can helpto prevent the envelope from sliding up chamber 480 when a vacuum isapplied within housing 442. Holding pins 488 can be screws, shoulderbolts, pins, or the like. Holding pins 488 can be inserted throughapertures 490 defined either in front wall 472, back wall 474, or both.A plurality of holding pins 480 can ensure that the envelope withinregistration apparatus 440 is properly registered before the envelope isremoved from the staging position into the insertion position forinsertion of the insert material into the envelope.

As can be seen in FIG. 6C, housing 442 can define entrance 468 such thatentrance 468 is wider than slit 462. The entrance can be chamfered so asto converge from its wider width W_(E) to slot width W_(S). Width W_(E)at the beginning of entrance 468 provides a greater opportunity forenvelopes being fed into registration apparatus 440 to correctly enterslit 462 thereby reducing the possibility of jams within the inserterstation 300. By having entrance 468 converge toward slit 462, an errantenvelope is more likely to be caught and directed into slit 462.Further, as shown in FIG. 6B, sealing block 486 can have a bottom wallwhich is cut at an angle to match the chamfer of entrance 468 leadinginto slit 462.

Vacuum connection 444 of registration apparatus 440 can take on manydifferent forms. The only requirement of vacuum connection 444 is thatit provides enough negative pressure within housing 442 to properlyalign, or register, the envelopes that enter housing 442. An example ofan embodiment of the vacuum connection is shown in the figures. Vacuumconnection 444 of registration apparatus 440 can include a housingfitting 492 having a housing opening 494 disposed therein to engagehousing 442 about second end 466. Housing opening 494 within housingfitting 492 can securely fit around second end 466 of housing 442 suchthat, when a negative pressure is pulled through housing fitting 492, itis also pulled through chamber 480 of housing 442. Housing fitting 492can further include a connector opening 496 which is in communicationwith housing opening 494.

Vacuum connection 444 can further include a connector fitting 498, whichcan be received in connector opening 496 of housing fitting 492. Vacuumconnection 444 can further include a vacuum tube 500, which can besecured to a vacuum source 502 that provides the negative pressure tohousing 442. Vacuum tube 500 can be securely fitted to connector fitting498 and also to vacuum source 502. Vacuum source 502 can be anystructure that can create a negative pressure within a range that willproperly align the envelope within registration apparatus 440. Forexample, vacuum source 502 can be a Gast blower, Model R 3105-1,manufactured by Gast Manufacturing, Inc., of Bent Harbor, Mich. Such ablower can create a negative pressure of up to about 0.5 pounds persquare inch for use within registration apparatus 440. However, a lesseror greater negative pressure may be used to register envelopes or othersheet articles.

FIGS. 7A and 7B show an envelope E with its rear end R disposed withinhousing 442 of registration apparatus 440. Registration apparatus 440can further include a stopper 504 that stops the progress of envelope Eas it enters slit 462 of housing 442. As envelope E enters slot 462,vacuum connection 444 can apply negative pressure within housing 442 toalign envelope E within staging position 460 before it is to be movedinto an insertion position for receipt of insert material. Vacuum source502 can supply a constant negative pressure within housing 442. Aspointed out above, the pressure should be great enough to properly alignenvelope E within registration apparatus 440 but not so great as tointerfere with the removal of envelope E from staging position 460 intoan insertion position. Rear end R of envelope E enters entrance 468 ofhousing 442 and into slit 462. Entrance 468 and slit 462 guide rear endR of envelope E under holding pins 488 that pass through back wall 474and front wall 472 above slit 462 into hollow chamber 480. The negativepressure provided by vacuum source 502 through vacuum tube 500,connector fitting 498 and housing fitting 492 can pull rear end R ofenvelope E against an interior 475 of the back wall 474 to alignenvelope E so that the mouth of envelope E is in a position to be openedfor receipt of the insert material when envelope E is moved to theinsertion position. Stopper 504 can also facilitate proper alignment ofenvelope E in staging position 460 before being moved to the insertionposition for receipt of insert material.

Vacuum connection 444 can include just a vacuum tube connected to thehousing 442 and a vacuum source 502 or it can take on other forms.Further, the opening within the housing around which the vacuumconnection is secured can be at other locations provided that theopening can provide the negative pressure into the chamber of thehousing for registration of the envelope. The chamber can also be anydesired shape that facilitates registration of envelope within thehousing. For example, the chamber can be just a rear portion of slit462.

FIG. 8 shows an enlarged view of a hollow chamber 480 within a housing442. An envelope E resides in slit 462 with a rear end R of envelope E(opposite flap F of envelope E) registered against the interior 475 ofback wall 474 of housing 442. The spacing between the holding pins 488and the envelope may be adjustable to prevent the rear end from curlingupward inside the chamber.

FIG. 9 shows registration apparatus 440 as it forms a portion ofvariable envelope opener apparatus 400 (see FIG. 3). Registrationapparatus 440 can further include a depth adjuster 506. Depth adjuster506 can move registration apparatus 440 relative to other portions ofvariable envelope opener 400 to permit different-sized envelopes to beprocessed within inserter station 300 (see FIG. 2). Depth adjuster 506can include a frame 508 through which a pair of lead screws 510 canreside. A holding bar 512 can be secured to top wall 476 of housing 442.Holding bar 512 can further reside on lead screws 510, which can bealigned parallel to one another. Holding bar 512 can include a pair ofactuating mechanisms 514 with each actuating mechanism 514 engaging oneof the lead screws 510 to permit movement of holding bar 512 along leadscrews 510. An adjustment wheel 516 can be secured to depth adjuster 506such that, when adjuster wheel 516 is turned, holding bar 512 throughthe actuating mechanisms 514 will move in a direction G along screws 510when adjuster wheel 516 is turned one way and will move in a direction Hwhen adjustment wheel 516 is turned in the other direction. As holdingbar 512 moves along lead screws 510, registration apparatus 440including housing 442 and at least a portion of vacuum connection 444move along with holding bar 512, while keeping a proper orientation withrespect to the flap plate (not shown) and first drop bar 450 and seconddrop bar 452. In this manner, different-sized envelopes can be processedby moving registration apparatus 440 back and forth within variableenvelope opener apparatus 400.

For example, as shown in FIG. 9, registration apparatus 440 can be movedto a back position for acceptance of a flats envelope. If a smallerenvelope is used, the adjustment wheel 516 can be turned so as to bringthe registration apparatus 440 closer to the flat plate (not shown) andfirst and second drop bars 450, 452. Similarly, the stopper 504 can befixed within variable envelope opener apparatus 400 at a position whereany envelope processed no matter what the size will come in contact withstopper 504.

Once an envelope E is registered within housing 442 of registrationapparatus 440, envelope E can reside in staging position 460 as shown inFIG. 10. Envelope E can enter staging position 460 with the face side FSof the body portion BP facing upward away from the inserter station 300.As discussed above, envelope E is held in staging position 460 byregistration housing 442 and flap plate 446. Registration housing 442,which has registered the envelope, holds rear end R of envelope E, whileflap F of envelope E resides on flap plate 446. When it is time for theenvelope to enter the insertion position, flap plate 446 can be moved ina direction I by actuator 448. First drop bar 450 and second drop bar452 can be then activated by actuators 451 and 453, respectively, topush envelope E out of staging position 460 into the insertion position.

While described in conjunction with a variable envelope openerapparatus, registration apparatus 440, described herein, can be used inany sheet or envelope handling apparatus. The registration apparatusonly needs a housing into which sheets or envelopes can enter and avacuum connection that provides a negative pressure to the housing toregister the sheets or envelopes. For example, the registrationapparatus can be in another location within a sheet processing machine,wherein folded sheets pass through a slit in the registration housing.As the folded sheets are passing through the slit, a negative pressurecan pull the folded sheets against the housing to register the foldedsheets. The utility of registration apparatus is not limited to theprocesses described here in the context of examples used.

The embodiments of the present disclosure shown in the drawings anddescribed above are exemplary of numerous embodiments that can be madewithin the scope of the appending claims. It is contemplated that theconfigurations for apparatuses for registering sheet articles within asheet processing machine can comprise numerous configurations other thanthose specifically disclosed. The scope of a patent issuing from thisdisclosure will be defined by the appended claims.

1. A registration apparatus for aligning a sheet article, theregistration apparatus comprising: (a) an elongated housing defining aslit along at least a portion of a length of the housing for receivingat least a portion of a sheet article, the housing further defining aninterior in communication with the slit; and (b) a vacuum connectionattached to the housing and in communication with the interior of thehousing, the vacuum connection configured for pulling a portion of asheet article within the slit to align the sheet article.
 2. Theregistration apparatus according to claim 1, wherein the slit in thehousing extends in a straight plane.
 3. The registration apparatusaccording to claim 1, wherein the slit in the housing extends in aconcave or convex shape.
 4. The registration apparatus according toclaim 1, wherein the interior of the housing comprises a hollow chamberrunning along the length of the housing, the chamber being incommunication with the slit and the opening.
 5. The registrationapparatus according to claim 4, wherein the housing comprises a frontwall, back wall, top wall and bottom wall that define the chamber. 6.The registration apparatus according to claim 5, wherein the slit isdefined in the front wall of the housing.
 7. The registration apparatusaccording to claim 6, wherein the housing and the vacuum connection areconfigured for creating negative pressure within the housing whereby thevacuum connection can pull a sheet article against an interior of theback wall of the housing.
 8. The registration apparatus according toclaim 4, wherein the housing comprises a first end and a second end withan opening leading into the chamber defined in both the first and secondends, the opening on the second end having the vacuum connectionattached thereto.
 9. The registration apparatus according to claim 8,wherein the slit extends through the first end of the housing definingan entrance in which the sheet article is received.
 10. The registrationapparatus according to claim 9, wherein the width of the entrance isgreater than the width of the slit.
 11. The registration apparatusaccording to claim 8, wherein the entrance converges to the slit. 12.The registration apparatus according to claim 9, wherein the slitextends across the length of the housing.
 13. The registration apparatusaccording to claim 4, further comprising a plurality of holding pinsdisposed in the housing proximal to the slit.
 14. The registrationapparatus according to claim 1, further comprising a sensor disposed onthe housing for determining the presence of a sheet article within theslit in the housing.
 15. The registration apparatus according to claim1, further comprising a stopper device positioned proximal to the slitwithin the housing configured to stop the envelope after entry of thesheet article into the slit.
 16. The registration apparatus according toclaim 1, further comprising a depth adjuster configured to move theregistration apparatus between different positions to accommodate fordifferent sized sheet articles.
 17. The registration apparatus accordingto claim 1, wherein a length of the slit in the housing is greater thana length of a sheet article to be received therein.
 18. A registrationapparatus for aligning an envelope in an inserter system, theregistration apparatus comprising: (a) an elongated housing having afront wall, back wall, top wall and bottom wall forming a chamber withinthe housing running along a length of the housing, the housing definingan opening at a first end and a second end of the housing and thehousing defining a slit along at least a portion of the length thatextends through the first end of the housing to define an entrancetherein, the slit and the entrance being configured to receive anenvelope; (b) a plurality of holding pins disposed in the housingproximal to the slit; and (c) a vacuum connection communicating with thechamber of the housing whereby the vacuum connection can cause anegative pressure within the housing for pulling an envelope into theslit to align the envelope within the housing by pulling the envelopeagainst an interior of the back wall of the housing.
 19. A method ofregistering a sheet article within a sheet processing machine, themethod comprising the steps of: (a) providing a registration apparatushaving a slit therein for receiving a sheet article; (b) advancing asheet article at least partially within the slit of the registrationapparatus; and (c) applying a negative pressure within the registrationapparatus to pull the sheet article into alignment within theregistration apparatus.
 20. The method according to claim 19, whereinthe negative pressure is continuously applied within an interior of thehousing.
 21. The method according to claim 19, wherein the negativepressure is removed when the sheet article is removed from the slit ofthe registration apparatus.
 22. The method according to claim 19,further comprising stopping the sheet article once it is fed into theslit of the registration apparatus before the step (c) of applying anegative pressure.
 23. The method according to claim 19, furthercomprising detecting the presence of a sheet article within theregistration apparatus.
 24. The method according to claim 23, wherein,if no sheet article is detected, step (b) of feeding a sheet articleinto the slit of registration apparatus occurs.
 25. The method accordingto claim 19, further comprising adjusting the position of theregistration apparatus to accommodate for different sized sheetarticles.
 26. A method of registering an envelope within an insertersystem, the method comprising the steps of: (a) providing a registrationapparatus having a slit therein for receiving envelopes; (b) advancingan envelope within the slit of the registration apparatus; (c) detectingthe presence of an envelope within the registration apparatus; (d)stopping the envelope once it is fed into the slit of the registrationapparatus; and (e) applying a negative pressure within the registrationapparatus, whereby the envelope is pulled into alignment within theregistration apparatus.